Modular Lubrication Unit

ABSTRACT

A modular lubrication unit for a rail lubrication distribution system includes a tank, a pump assembly, and a controller. The pump assembly is in fluid communication with the tank and the controller is in communication with the pump assembly for controlling the pump assembly. The controller is enclosed within a panel and the tank is self-contained and movable relative to the panel.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.61/158,418, filed Mar. 9, 2009, the entire content of which is herebyincorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to lubrication of railroad tracks and,more particularly, to a modular lubrication unit for supplyinglubricant, such as grease, to railroad rails.

2. Description of Related Art

In the operation of railroads, it has long been the practice to applylubricant or friction modifier materials onto railroad rails, such as tothe top of the rails or sides of the rails at curves, turnouts,switches, and in some cases, the section of a track immediately before aswitch, and periodically spaced along the length of the track. Suchlubricants and friction modifier materials, such as grease, can eitherreduce or increase the friction where necessary to improve trainperformance and reduce wear on both the rails and the train wheels.Lubricant is typically pumped from a nearby central pump station to arail applicator device for applying lubricant to the railroad rails.Such rail applicator devices are disclosed in U.S. Pat. No. 5,394,958,which is hereby incorporated by reference. The pump station, which istypically housed in a small enclosure, generally includes a tank and atleast one pump that draws lubricant from the tank. The pump is typicallymounted to a wall of the enclosure, wherein access to the pump formaintenance purposes is easily attainable.

In the railroad industry, railroads typically have different prioritiesand solutions to their specific problems. Oftentimes lubricant may beneeded at different locations along the railroad track that was notcontemplated during the design stage of the railroad. Because the priorart pump stations are integrated as one complete unit, a new pumpstation along with an enclosure would have to be provided. If morelubricant is required at another location of a railroad track or even atthe same location, a second complete lubrication unit may have to beinstalled. Either another small enclosure would have to be installed, oran additional lubrication pump would have to be positioned within thelimited space of the one enclosure.

SUMMARY OF THE INVENTION

In one embodiment, a modular lubrication unit for a rail lubricationdistribution system includes a tank, a pump assembly, and a controller.The pump assembly is in fluid communication with the tank and thecontroller is in communication with the pump assembly for controllingthe pump assembly. The controller is enclosed within a panel and thetank is self-contained and movable relative to the panel.

The pump assembly may be attached to the tank via a connector. The pumpassembly may include a pump and a motor with the pump assembly beingpositioned within an enclosure. The pump assembly may be attached to aside of the tank and the panel may be spaced from the tank. The panelmay also be positioned on a pair of spaced apart legs with a bottom ofthe tank defining a recess. The tank may be positioned on a support andthe support and the bottom of the tank defining a recess. The pumpassembly may be positioned within an enclosure with the enclosure beingattached to the bottom of the tank within the recess. The enclosure maybe supported via bracket.

In a further embodiment, a modular lubrication unit for a raillubrication distribution system includes first and second tanks, firstand second pump assemblies, and a controller. The first tank is spacedfrom the second tank and the first pump assembly is in fluidcommunication with the first tank and the second pump assembly is influid communication with the second tank. The controller is incommunication with the first and second pump assemblies for controllingthe first and second pump assemblies. The controller is enclosed withina panel, where the first and second tanks are self-contained and movablerelative to the panel.

The first pump assembly may be attached to the first tank via aconnection and the second pump assembly may be connected to the secondtank via a connector. Each pump assembly may include a pump and a motorwith each pump assembly being positioned within an enclosure. The firstpump assembly may be attached to a side of the first tank and the secondpump assembly may be attached to a side of the second tank. The panelmay be positioned between the first and second pump assemblies, wherethe first and second pump assemblies are supported by first and secondbrackets. The panel may be positioned on a pair of spaced apart legs.

In another embodiment, a method includes: providing a tank, a pumpassembly, and a controller; positioning a pump and a motor within anenclosure to define the pump assembly; connecting the pump assembly tothe tank such that the pump assembly is in fluid communication with thetank; positioning the controller within a panel; positioning the panelat a location that is adjacent to and spaced from the tank; andactuating the pump assembly via the controller to supply lubricant fromthe tank to a rail lubrication distribution system. The method mayfurther include removing the pump assembly and replacing the pumpassembly with a different pump assembly and removing the tank by movingthe tank relative to the panel and replacing the tank with a differenttank.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a modular lubrication unit according toone embodiment of the present invention;

FIG. 2 is a top view of the modular lubrication unit shown in FIG. 1;

FIG. 3 is a side view of the modular lubrication unit shown in FIG. 1;

FIG. 4 is a front view of the modular lubrication unit shown in FIG. 1;

FIG. 5 is a perspective view of the modular lubrication unit shown inFIG. 1, showing a door in the closed position;

FIG. 6 is a perspective view of a pump assembly of the modularlubrication unit shown in FIG. 1;

FIG. 7 is a side view of the pump assembly shown in FIG. 6;

FIG. 8 is a front view of the pump assembly shown in FIG. 6;

FIG. 9 is top view of the pump assembly shown in FIG. 6;

FIG. 10 is a side view of the pump assembly shown in FIG. 6, showing theinterior of an enclosure;

FIG. 11 is a front view of the pump assembly shown in FIG. 6, showingthe interior of an enclosure;

FIG. 12 is top view of the pump assembly shown in FIG. 6, showing theinterior of an enclosure;

FIG. 13 is a perspective view of a modular lubrication unit according toa further embodiment of the present invention;

FIG. 14 is a side view of the modular lubrication unit shown in FIG. 13;

FIG. 15 is a front view of the modular lubrication unit shown in FIG.13;

FIG. 16 is a top view of the modular lubrication unit shown in FIG. 13;

FIG. 17 is a perspective view of a pump assembly of the modularlubrication unit shown in FIG. 13;

FIG. 18 is a side view of the pump assembly shown in FIG. 17;

FIG. 19 is a front view of the pump assembly shown in FIG. 17;

FIG. 20 is a top view of the pump assembly shown in FIG. 17;

FIG. 21 is a is a side view of the pump assembly shown in FIG. 17,showing the interior of an enclosure;

FIG. 22 is a front view of the pump assembly shown in FIG. 17, showingthe interior of an enclosure;

FIG. 23 is a top view of the pump assembly shown in FIG. 17, showing theinterior of an enclosure;

FIG. 24 is a perspective view of a modular lubrication unit according toanother embodiment of the present invention;

FIG. 25 is a top view of the modular lubrication unit shown in FIG. 24;

FIG. 26 is a front view of the modular lubrication unit shown in FIG.24;

FIG. 27 is a side view of the modular lubrication unit shown in FIG. 24;

FIG. 28 is a side view of modular lubrication unit according to yetanother embodiment of the present invention, showing the interior of anenclosure;

FIG. 29 is a front view of the modular lubrication unit shown in FIG.28;

FIG. 30 is a perspective view of a modular lubrication unit according toa further embodiment of the present invention; and

FIG. 31 is a side view of the modular lubrication unit shown in FIG. 30.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of the description hereinafter, spatial orientation terms,if used, shall relate to the referenced embodiment as it is oriented inthe accompanying drawing figures or otherwise described in the followingdetailed description. However, it is to be understood that theembodiments described hereinafter may assume many alternative variationsand embodiments. It is also to be understood that the specific devicesillustrated in the accompanying drawing figures and described herein aresimply exemplary and should not be considered as limiting.

Referring to FIGS. 1-12, one embodiment of a modular lubrication unit 10for supplying pressurized lubricant, such as grease or frictionmodifying material, is provided. The modular lubrication unit 10supplies lubricant to an applicator device (not shown) for applicationof the lubricant onto the railroad rails. The lubrication unit 10includes a lubricant tank 12, a pump assembly 14 attached to and influid communication with the tank 12 and a controller 16 incommunication with the pump assembly 14 for supplying the lubricant tothe railroad rails. The controller 16 is electronically connected to thepump assembly 14 via a cable 17 for controlling the pump assembly 14.The tank 12 has spaced-apart legs 18 beneath a bottom 19 of the tank 12defining a recess 20 therebetween, although the tank 12 may also have aflat bottom or other suitable bottom configurations. The recess 20enables the tank 12 to be easily moved, such as via the forks of aforklift truck received within the recess 20. The tank 12 may also bepositioned on a support 22, such as channel bars, having channels 24(shown in FIGS. 13-16) for receiving the forks of a forklift truckwithin the channels 24. The bottom 19 of the tank 12 and the support 22also define a recess 26. The tank 12 may also be a tote. Such tanks ortotes may have various sizes and shapes. The tank 12 may also include afunnel-shaped insert (not shown) received therein for funnelinglubricant toward a bottom outlet of the tank. Further, a tank enclosure(not shown) may also be used to house the tank. The tank 12 isself-contained and movable relative to the panel 42, such that the tank12 can be readily replaced with a different tank for containing adifferent type of lubricant, if required. The different tank may be adifferent shape or size than the tank 12 to hold a different volume oflubricant than the tank 12. The tank 12 may be readily separated fromthe panel 42 and pump assembly 14 by, for example, removing a mechanicalfastener arrangement that secures the tank 12 relative to the panel 42and the pump assembly 14.

Referring to FIGS. 6-12, the pump assembly 14 may include a pump 30 anda motor 32 attached thereto. The pump assembly 14 is shown housed in anenclosure 34 having openings O therein for receiving inlet and outlettubing or piping (not shown). The enclosure 34 may be attached to aholding bracket 38 with the holding bracket 38 supporting the enclosure34. The bracket 38 may also be attached directly to the tank 12 usingany suitable fastening arrangement, such as mechanical fastening, foreasy removal from the tank 12. The pump assembly 14 is in fluidcommunication with the tank 12 via a connector 36 that attaches the pumpassembly 14 to the tank. The present invention permits different pumpassemblies 14 to be utilized with the tank 12. The connector 36 isattached to a side 40 of the tank 12, although the connector may beattached to other portions of tank or may be attached to the tank 12through piping. The pump assembly 14 is protected from the environmentvia the enclosure 34, which may provide protection against corrosion,moisture and other hazards that can damage or reduce the normal lifecycle of the pump assembly 14. For example, the enclosure 34 can be madeof a polymeric material or corrosion-resistant metal.

Referring to FIGS. 1-5, the controller 16 is typically housed in anelectrical box or panel 42 having an access door 44 therein for easyaccess to the controls by an operator. The access door 44 has an openposition (shown in FIG. 1) and a closed position (shown in FIG. 5). Thelubrication unit 10 may include timers, flow meters, level sensors,manifolds, flow dividers and microprocessors, and the like, forcontrolling the amount and frequency of lubricant supplied to therailroad rails via the controller 16. The panel 42 is positionedadjacent to and spaced from the tank 12, although the panel 42 may alsobe directly attached to the tank 12. The panel 42 includes channels orlegs L whereby the forks of a forklift truck can be inserted thereinthus lifting and/or transporting the panel 42. The present inventionpermits different controllers to be used with pump assemblies 14 andtanks 12 creating a modular design, where the present invention createsa true modular arrangement.

In operation, lubricant from the tank 12 is pumped out of the tank 12from a bottom side thereof via the pump assembly 14 thus supplyingpressurized lubricant to a rail applicator device and onto railroadrails. An operator (not shown) can program the controller 16 via theaccess door 44 and control the flow rates and/or frequency ofapplication. The controller 16 may be attached to the tank 12 oradjacent to and spaced from the tank 12. The panel 42 and controller 16are self-contained and may be readily separated from the tank 12. Whentransporting the unit 10, the un-attached panel 42 and controller 16 canbe transported separately from the tank 12.

FIGS. 13-23 show a further embodiment of a modular lubrication unit 10Athat is similar the lubrication unit 10. Like reference numerals areused for like parts. The lubrication unit 10A also includes alubrication tank 12, a pump assembly 14 and controller 16 which issimilar to lubrication unit 10. However, the pump assembly 14 oflubrication unit 10A is attached to the bottom 19 of the tank 12. Inparticular, the pump assembly 14 is positioned within the enclosure 34with the enclosure 34 being secured to the bottom 19 of the tank 12.Typically, this type of arrangement will be used with highly viscousliquids such as grease. Although not shown, a holding bracket may beused to support the pump assembly 14 or to attach the pump assembly 14to the bottom of the tank 12. The support 22, such as channel bars,positioned beneath the bottom 19 of the tank 12 raises the tank 12 offof the ground level and defines the recess 26 such that the pumpassembly 14 is also spaced away from the ground level and positionedwithin the recess 26. Access to the pump assembly 14 for maintenancepurposes may be accomplished by lifting the unit 10A with the forks of aforklift truck. In this embodiment, the tank 12 can also have acone-shaped insert (not shown) for funneling lubricant to the bottom ofthe tank 12 into an inlet of the pump assembly 14.

FIGS. 24-27 show another embodiment of a modular lubrication unit 10Bthat is similar to lubrication unit 10A. Like reference numerals areused for like parts. Lubrication unit 10B includes first and secondtanks 12 with the tanks 12 being spaced from each other. First andsecond pump assemblies 14 are attached to the sides 40 of the respectivetanks 12 with the first and second pump assemblies being in fluidcommunication with the respective tanks 12. A controller 16 is incommunication with the first and second pump assemblies 14 forcontrolling the first and second pump assemblies 14. The controller 16is enclosed within a panel 42. The first and second tanks 12 areself-contained and movable relative to the panel 42 such that the tanks12 can be readily replaced with different tanks for containing differenttypes of lubricant if required. The first and second pump assemblies 14may be supported by brackets 38. The panel 42 and controller 16 arepositioned between the first and second pump assemblies 14 and arepositioned on spaced-apart legs L. The controller 16 controls the firstand second pump assemblies 14, although the controller may control oneor more pump assemblies for distribution of lubricant from one or moretanks.

In particular, one of the tanks 12 may contain a first lubricant and theother tank 12 may include a second lubricant. For example, the firstlubricant may be a summer-formulated lubricant and the second lubricantmay be a winter-formulated lubricant. The controller 16 may be incommunication with various temperature sensors (not shown) to determinethe temperature conditions. During colder weather, the controller 16 mayactuate the pump assembly 14 connected to the tank 12 that contains thewinter-formulated lubricant for distribution to the rail lubricationequipment. During warmer weather, the controller 16 may actuate the pumpassembly 14 connected to the tank that contains the summer-formulatedlubricant for distribution to the rail lubrication equipment. The pumpassemblies 14 may be similar, but can be operated differently based onthe lubricant the pump assemblies 14 are pumping. For instance, the pumpassemblies 14 may have different pumping intervals and cycles dependingon the type of lubricant being pumped. Accordingly, the controller 16can selectively distribute a suitable lubricant from the plurality oftanks 12 based on the particular temperature conditions.

FIGS. 28 and 29 show yet another embodiment of a modular lubricationunit 10C that is similar to the lubrication units 10, 10A, and 10B. Likereference numerals are used for like parts. Lubrication unit 10Cincludes a tank 12, which is shown as a tote, a pump assembly 14, and acontroller 16. The controller 16 and the pump assembly 14 are positionedwithin a panel 42 rather than providing a separate enclosure for thepump assembly 14. The pump assembly 14 is connected to and in fluidcommunication with the tank via piping 48. The controller 16 isconnected to the pump assembly 14 to allow the controller 16 to controlthe operation of the pump assembly 14.

FIGS. 30 and 31 show a further embodiment of a modular lubrication unit10D that is similar to the lubrication units 10, 10A, 10B, and 10C. Likereference numerals are used for like parts. Lubrication unit 10Cincludes a tank 12, a pair of pump assemblies 14, and a controller 16.The controller 16 is positioned within a panel 42 as discussed above inconnection with lubrication units 10, 10A, 10B, and 10C. The panel 42 issecured to the upper portion of the tank 12 to define a space 50 beneaththe panel 42. Although not shown, the controller 16 is connected to thepump assemblies 14 to allow the controller 16 to control the operationof the pump assemblies 14. Each of the pump assemblies 14 are positionedwithin separate enclosures 34 with the pump assemblies 14 beingconnected to and in fluid communication with the tank 12 via a connector36. In particular, the connector 36 of the lubrication unit 10D is aT-shaped piping assembly that is secured to a single outlet O of thetank 12 with each pump assembly 14 being separately connected to theconnector 36. The single tank 12 of the lubrication unit 10D may feedmultiple tracks of lubrication equipment with one of the pump assemblies14 supplying lubricant to a first set of lubrication equipment and theother pump assembly 14 supplying lubricant to a second set oflubrication equipment.

Although not shown, the modular lubrication units 10, 10A, 10B, 10C maybe powered via a DC solar power arrangement, through connection viacabling to an AC or DC power source, or through any other suitable powersource options.

In a further embodiment, a method includes providing a tank, a pumpassembly, and a controller; positioning a pump 30 and a motor 32 withinan enclosure 34 to define the pump assembly 14; connecting the pumpassembly 14 to the tank 12 such that the pump assembly 14 is in fluidcommunication with the tank 12; and positioning the controller 16 withina panel 42. The method also may include positioning the panel 42 atlocation adjacent to and spaced from the tank 12 and actuating the pumpassembly 14 via the controller 16 to supply lubricant from the tank 12to a rail lubrication distribution system. The method may also includeremoving the pump assembly 14 and replacing the pump assembly with adifferent pump assembly 14 and removing the tank 12 by moving the tank12 relative to the panel 42 and replacing the tank with a different tank12. In particular, the pump assembly 14 and tank 12 may be readilyremoved and replaced with different pump assemblies or tank toaccommodate various types of lubricants.

The advantage of having self-contained tanks with pump assembliesmounted thereto is that the tank and/or pump assembly can be switchedout for another self-contained tank and pump assembly having differentgrade lubricants therein. Hence, a modular design is provided thatallows a lubrication system to be customized based upon the customer'sneeds. The present invention provides a modular arrangement with a tank12, pump assembly 14, and controller 16 creating a modular lubricationunit, where the controller 16, pump assembly 14, and tank 12 can beformed from different size tanks, size pumps, and controllers dependingon the requirements at the point of application. By ensuring that thecustomer can optimize the lubrication unit to suit their specific needs,the modular unit will increase the effectiveness of the system. That is,specific tanks, pumps and controllers can be connected together toresult in a specific lubrication system. As a result, inventory can beminimized via the present modular system. Further, the self-containedlubrication units can be easily transported or shipped anywhere on arailroad line and then easily installed at the site where thelubrication system is to be installed.

This invention has been described with reference to the preferredembodiments. Obvious modifications and alterations will occur to othersupon reading and understanding the preceding detailed description. It isintended that the invention be construed as including all suchmodifications and alterations.

1. A modular lubrication unit for a rail lubrication distribution systemcomprising: a tank; a pump assembly in fluid communication with thetank; and a controller in communication with the pump assembly forcontrolling the pump assembly, the controller being enclosed within apanel, wherein the tank is self-contained and movable relative to thepanel.
 2. The modular lubrication unit of claim 1, wherein the pumpassembly is attached to the tank via a connector.
 3. The modularlubrication unit of claim 2, wherein the pump assembly comprises a pumpand a motor, the pump assembly being positioned within an enclosure. 4.The modular lubrication unit of claim 1, wherein the pump assembly isattached to a side of the tank.
 5. The modular lubrication unit of claim1, wherein the panel is spaced from the tank.
 6. The modular lubricationunit of claim 5, wherein the panel is positioned on a pair of spacedapart legs.
 7. The modular lubrication unit of claim 1, wherein a bottomof the tank defines a recess.
 8. The modular lubrication unit of claim1, wherein the tank is positioned on a support, the support and thebottom of the tank defining a recess.
 9. The modular lubrication unit ofclaim 8, wherein the pump assembly is positioned within an enclosure,the enclosure being attached to the bottom of the tank within therecess.
 10. The modular lubrication unit of claim 3, wherein theenclosure is supported via a bracket.
 11. A modular lubrication unit fora rail lubrication distribution system comprising: first and secondtanks, the first tank being spaced from the second tank; first andsecond pump assemblies, the first pump assembly being in fluidcommunication with the first tank and the second pump assembly being influid communication with the second tank; a controller in communicationwith the first and second pump assemblies for controlling the first andsecond pump assemblies, the controller being enclosed within a panel,wherein the first and second tanks are self-contained and movablerelative to the panel.
 12. The modular lubrication unit of claim 11,wherein the first pump assembly is attached to the first tank via aconnector and the second pump assembly is connected to the second tankvia a connector.
 13. The modular lubrication unit of claim 12, whereineach pump assembly comprises a pump and a motor, each pump assemblybeing positioned within an enclosure.
 14. The modular lubrication unitof claim 11, wherein the first pump assembly is attached to a side ofthe first tank, and the second pump assembly is attached to a side ofthe second tank.
 15. The modular lubrication unit of claim 14, whereinthe panel is positioned between the first and second pump assemblies.16. The modular lubrication unit of claim 15, wherein the first andsecond pump assemblies are supported by first and second brackets. 17.The modular lubrication unit of claim 16, wherein the panel ispositioned on a pair of spaced apart legs.
 18. A method comprising:providing a tank, a pump assembly, and a controller; positioning a pumpand a motor within an enclosure to define the pump assembly; connectingthe pump assembly to the tank such that the pump assembly is in fluidcommunication with the tank; positioning the controller within a panel;positioning the panel at a location that is adjacent to and spaced fromthe tank; actuating the pump assembly via the controller to supplylubricant from the tank to a rail lubrication distribution system. 19.The method of claim 18, further comprising: removing the pump assemblyand replacing the pump assembly with a different pump assembly.
 20. Themethod of claim 19, further comprising: removing the tank by moving thetank relative to the panel and replacing the tank with a different tank.